Wax-less, integral skin toilet gasket

ABSTRACT

A wax-less integral skin toilet gasket. The gasket has a ring shaped upper portion and a truncated conical extension integrally extending downwardly therefrom. Fastening bolts extend through the toilet flange attached to the floor conduit with the bolts then extending through the ring shaped configuration and attached to the toilet base.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of gasketspositioned between the toilet base and toilet flange.

2. Description of the Prior Art

A gasket is positioned between the outlet base of a toilet and theupwardly facing toilet flange provided on the floor drain. The object ofthe gasket is to provide a water and gas seal; however, many of theprior art gaskets develop leaks. Frequently a gasket is stored in a hightemperature environment prior to installation of the gasket therebycausing the gasket to degrade. In the event the gasket is subjected tohigh temperatures or if the toilet is rocked back and forth then leaksmay develop.

The standard gasket is produced from pliable wax. If the toilet has tobe removed for repair, the plumber must manually remove and scrape offthe wax gasket prior to installation of a new gasket. Further, thegasket is difficult to observe when the toilet is positioned upon thefloor drain providing for the possibility that the gasket will not bealigned with respect to the toilet base and the flange on the floordrain. What is needed is a gasket that exhibits flexibility whilemaintaining a seal even if the toilet is rocked relative to the floorand which also minimizes degradation of the gasket in the event thegasket is stored or used in a relatively high temperature environment.Further, it is desirable to have a gasket that is repositionable andreusable in the event the toilet must be removed from the floor andreinstalled.

Currently there are a number of solutions for a toilet flange gasket.Some of these solutions use a wax ring, but these solutions fail to meetthe need of the industry because the wax is not resilient. Othersolutions attempt to use open cell foam encased in wax. This issimilarly unable to meet the industry needs. Still other solutionsattempt to use a pvc extension which is glued to the bottom of thetoilet around the horn. While this solution is wax-less, there aremultiple flange outlet sizes that need to be known to match the propergasket to the flange, also it will not stick well to the bottom of atoilet that has been previously positioned on a wax ring. Therefore, itssuitability is primarily limited to use on new toilet installation andnot easily used in repositioning an existing toilet.

A number of U.S. patents have been granted on toilet gaskets. U.S. Pat.No. 6,694,537 issued to Telles discloses a polyethylene foam gaskethaving resilience and the ability to recover substantially its originalshape and thickness after compression loading. The U.S. Pat. No.6,691,331 issued to Telles discloses an elastomeric gasket locatedbetween the toilet bowl and the floor. The U.S. Pat. No. 3,821,820issued to Thompson discloses a toilet gasket having a ring of wax-likematerial. The U.S. Pat. No. 4,482,161 issued to Izzi, discloses a toiletgasket designed to replace the conventionally used wax sealing rings andhaving a main body of rubber like material, such as polyvinyl chloride.The U.S. Patent Publication 2006/0225195 discloses an anti-microbialpackage for use in toilet wax gaskets. U.S. Pat. No. 5,114,980 issued toLii et al. discloses a polyurethane integral skin foam for use inproducing various products.

The present invention is superior when compared to other known devicesand solutions because the present invention provides a suitable sealwithout the use of wax. Furthermore, the present invention isrepositionable, can be used over a wide temperature range, provides aseal on various flange configurations relative to floor grade and isantimicrobial. In addition, the present invention can be stacked toprovide a seal when the gap is too large for one gasket. For additionalprotection, the gaskets can be siliconed together or coated withplumbers grease. The present invention is unique in that it isstructurally different from other known devices and solutions. Morespecifically, the present invention is unique due to being made ofintegral skin polyurethane foam.

SUMMARY OF THE INVENTION

A wax-less, repositionable gasket provides a liquid and gas seal betweena toilet base and a toilet flange that is provided on a drain conduit towhich the toilet base is mountable. The gasket has a main body ofpolyurethane foam construction that extends throughout the main body. Ithas a ring shaped upper portion for acting as a seal between a toiletbase and a toilet flange on a drain conduit and a truncated conicalextension integral with the ring shape. The extension is positioned intothe drain conduit to direct liquid flow. The main body has an outer skinintegral therewith providing structural stability to the constructionmaintaining a seal despite varying loads thereon by the toilet base anddespite repositioning thereof.

It is an object of the present invention to provide a new and improvedgasket for positioning between a toilet base and flange of a floordrain.

A further object of the present invention is to provide a wax-lessrepositionable toilet gasket.

In addition, it is an object of the present invention to provide awax-less toilet gasket having a main body with an outer skin insuringstructural integrity.

Related objects and advantages of the present invention will be apparentfrom the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the gasket incorporating the presentinvention positioned between the toilet flange attached to the floordrain and the toilet outlet base.

FIG. 2 is a side view of the combination shown in FIG. 1.

FIG. 3 is a cross-sectional view taken along the line 3-3 of FIG. 2 andviewed in the direction of the arrows.

FIG. 4 is a side view of a pair of identical gaskets 70 and 72 stackedtogether.

DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiment illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated device, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

Referring now more particularly to the drawings, there is shown awax-less repositionable toilet flange gasket 15 positioned between atoilet flange 16 attached to the floor drain conduit 17 and the toiletbase 18, in turn, attached to the toilet.

Gasket 15 includes a main body 19 of polyurethane foam constructionwhich extends throughout the main body. Main body 19 includes a ringshaped upper portion 20 integrally attached to a truncated conicalextension 21 that is extendable into the toilet flange 16, in turn,extended into and fixedly attached to the drain conduit 17. Extension 21directs liquid flow into toilet flange 16 and conduit 17.

Ring shaped upper portion includes a outer top curved surface 22extending downwardly to a vertical surface 23 with both surfaces 22 and23 being continuous and extending around the longitudinal center axis24. Upper portion 20 forms a hollow interior 25 receiving the fluid fromthe downwardly extending extension 26 of toilet base 18. Base extension26 fits into hollow interior 25 that is formed by a top inner curvedsurface 27 that extends downwardly to a planar surface 29 extendingthrough the length of extension 21. Planar surface 29 and curved surface27 extend continuously around axis 24. The junction of the outer curvedsurface 22 and the inner curved surface 27 forms an upwardly facing topsurface 28 that contacts the downwardly facing flat surface 30 of flange31 of toilet base 18 effecting a liquid and gas tight seal betweentoilet base 18 and gasket 15. The gasket, toilet base and toilet flangeare shown in separated positions in the drawings in order to moreclearly show the various components; however, it is to be understoodthat in use, base 18 is in contact with gasket 15 which, in turn, is incontact with toilet flange 16.

A downwardly facing flat or planar surface 33 extends continuouslyaround extension 21 being joined at its outer edge portion to surface 23and on its inner edge portion to extension 21. Extension 21 is atruncated, downwardly extending, cone forming a hollow passage throughwhich the liquid and gas flow. Extension 21 has an outside continuoussurface 34 parallel to the inner continuous flat surface 29. The outsidediameter of the extension formed by surface 34 along with the insidediameter of the extension formed by surface 29 both decrease in diameteras the extension extends downwardly. Surface 29 is blended into innercurved surface 27 whereas the outside continuous surface 34 is at anoblique angle to planar surface 33.

Building floor 40 may include a bottom wood floor frame 41 havingpositioned thereon a finished floor 42 of suitable material, such astile. Toilet flange 16 has a continuous ring shaped flange 43 integrallyjoined to a cylindrical pipe extension 44, in turn, extending into drainconduit 17. Extension 44 is sealed to conduit 17 by any number ofconventional means. Floor 40 includes a hole through which extension 44extends with flange 43 then being positioned atop floor 40 or in somecases being recessed into the floor.

A pair of conventional bolts 46 and 47 have heads 48 extended into holes49 provided 180 degrees apart on flange 16 with one such hole 49 beingshown in FIG. 1. A pair of accurate shaped slots extend from each hole49 with each slot having a counter bore or enlarged lower opening 50enabling the head 48 of each bolt to be extended through openings 49while the shank of the bolt is extended upwardly. The shanks may bemoved along the lengths of the accurate slots to distance the bolt headapart from hole 49 preventing accidental disengagement of the bolt fromthe flange. Each bolt shank then extends through bolt holes 52 and 53located 180 degrees apart on the upper portion of the gasket. Holes 52and 53 extend through the outer curved surface 22 and the downwardlyfacing planar surface 33 of the ring shaped configuration. Outer curvedsurface 22 is positioned radially outward of extension 21.

Once the gasket is installed to the toilet flange by the extendingextension 21 into extension 44 and with the bolt shanks passing throughholes 52 and 53, toilet base 18 is mounted to the bolts. Toilet base 18includes a pair of bolt holes 56 and 57 located 180 degrees apart withthe bolt shanks then extending above flange 31 whereat conventionalhexagonally shaped nuts 59 (FIG. 1) are threadedly mounted to the boltshanks thereby forcing toilet base 31 onto gasket 15 and, in turn, thegasket onto toilet flange 16 compressing the gasket and providing theliquid and gas seal between the toilet and conduit 17. Planar surface 33contacts the upwardly facing surface of flange 43 affecting a liquid andgas seal between the gasket and the toilet flange 16.

The truncated conical shaped extension 21 of gasket 15 is particularlyuseful in allowing gaskets to be stacked together. For example, topgasket 70 (FIG. 4) includes an extension 71 extending down through thering shaped upper portion and into extension 73 of lower gasket 72. Inthe event the distance between toilet base 18 and toilet flange 16 isgreater than the height 80 (FIG. 2), then a pair of gaskets 70 and 72(FIG. 4) identical to gasket 15 may be stacked together. In such a case,the top surface 28 seals against toilet base 18 whereas the bottomplanar surface 33 of top gasket 70 seals against the top surface 28 ofbottom gasket 72 and the bottom planar surface 33 of bottom gasket 72seals against toilet flange 16 in a manner identical to that describedfor gasket 15.

The combination shown in the drawing consisting of the toilet base,drain conduit, building floor and gasket is particularly advantageous toaccommodate variations and positioning of the flange 43 of toilet flange16. That is, flange 43 may be positioned completely on top of the upperfloor layer 42 or may be recessed as shown in FIG. 3 with the topsurface of the toilet flange 16 being located slightly above the topsurface of floor layer 42. Likewise, the top surface of flange 43 may bepositioned beneath the top surface of floor layer 42 while stillallowing the gasket to ensure a tight seal between the toilet base andtoilet flange. This is true since the thickness of the ring shaped mainbody is sufficient to allow for variations in the positioning of toiletflange 16. In one embodiment, the thickness 80 (FIG. 2) has a thicknessof at least one inch to accommodate variations and positioning of thetoilet base relative to the upper surface of floor layer 42. By ensuringthat dimension 80 is at least one inch between the top surface 28 andplanar surface 33, the seal is accomplished with toilet flange 43regardless of variations and positioning of the toilet flange 43relative to the building floor 42 even through flange 43 is above orbelow the top surface of floor layer 42 providing the distance betweenbottom surface 30 of toilet base 18 and toilet flange 16 is not greaterthan one inch.

Gasket 15 is composed throughout of a self skinning polyurethane foam(polyurethane integral skin foam). Integral skin foam is flexible on theinside but tough on the outside. It has been used for athletic equipmentand office seating applications. Such a product is available fromRenosol of Saline, Minn. 48176. The material is also available fromJones & Vining, Inc. of Brockton, Mass. The polyurethane may be composedof the reaction product of a polyether polyol blend and an isocyanate.The polyol blend consists of a combination of polyether polyols(polyhydroxyl or polyamine compounds), surfactants, chain extenders,catalysts and any single or combination of physical and/or chemicalblowing agents. The isocyanate may be either an MDI (diphenylethanediisocanate) or TDI (toluene diisocynate) or any combination thereof.The molded density of the product skin should be between 0.04 and 0.40gm/cc. The product will perform over a temperature range of 0 to 200degrees Fahrenheit. One integral skin foam is available under the namePoly 900 IS/Bayflex 976 A Iso from BayOne Urethane Systems LLC, St.Louis Mo. with parts typically molded to a density of 14-20 pcf. Thepolyurethane integral foam may be polyether based having BHT (butylatedhydroxyl-toluene) providing an anti-microbial construction for thegasket.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected. For example, plumbers grease may be appliedto the top surface of the gasket main body 19 and/or the bottom surface33 of the gasket main body to achieve a superior seal.

1. A wax-less, repositionable gasket for providing a liquid and gas sealbetween a toilet base and a toilet flange provided on a drain conduit towhich the toilet base is mountable comprising: a main body ofpolyurethane foam construction extending throughout said main body andhaving a ring shape upper portion for acting as a seal between a toiletbase and a toilet flange on a drain conduit and a truncated conicalextension integral with said ring shape upper portion that is extendableinto said toilet flange on said drain conduit to direct liquid flow,said main body has an outer skin integral therewith providing structuralstability to said construction maintaining a seal despite varying loadsthereon by said toilet base and despite repositioning thereof.
 2. Thegasket of claim 1 wherein said main body is self skinning polyurethanefoam.
 3. The gasket of claim 1 wherein said main body is polyurethaneintegral skin foam.
 4. The gasket of claim 1 wherein said gasket isstackable with an identical gasket by extending said truncated conicalextension of said main body into an identical truncated conicalextension of said identical gasket.
 5. The gasket of claim 1 whereinsaid main body includes a pair of passages extending through said ringshape upper portion for receiving bolts securing said toilet base andtoilet flange together with said main body there between.
 6. The gasketof claim 5 wherein said ring shape upper portion of said main bodyincludes an outer curved surface and inner curved surface portions ofwhich face upwardly toward said toilet base when said toilet base isseated thereatop effecting a seal between said portions and said toiletbase, said outer curved surface and said flat surface are positionedradially outwardly of said extension, said main body further has aplanar downwardly facing surface extending continuously around saidextension and seatable atop said toilet flange effecting a seal betweensaid planar surface and said toilet flange with said passages extendingthrough said outer curved surface and said planar surface, saidtruncated conical extension is hollow forming a liquid passage and hasan outside continuous surface of an outside diameter and insidecontinuous surface of an inside diameter both of which decrease indiameter as said extension extends downwardly, said inside curvedsurface blends into said inside continuous surface whereas said outsidecontinuous surface is joined at an oblique angle to said planar surface.7. The gasket of claim 6 wherein said main body is self skinningpolyurethane foam.
 8. The gasket of claim 6 wherein said main body ispolyurethane integral skin foam.
 9. The gasket of claim 7 wherein saidring shape upper portion has a thickness of at least one inch toaccommodate variations in positioning of said toilet base.
 10. Thecombination of: a toilet base; a drain conduit having a toilet flange; abuilding floor with a top surface and having said drain conduitpositioned in said floor; and, a main body of foam constructionextending throughout said main body and having a ring shape upperportion with an upper surface for acting as a seal with said toilet baseand a lower surface for acting as a seal with said toilet flange andfurther having a truncated conical extension integral with said ringshape upper portion that is extendable into said toilet flange on saiddrain conduit to direct liquid flow, said main body has an outer skinintegral therewith providing structural stability to said constructionmaintaining a seal despite varying loads thereon by said toilet base anddespite repositioning thereof.
 11. The gasket of claim 10 wherein saidmain body is self skinning polyurethane foam.
 12. The gasket of claim 10wherein said main body is polyurethane integral skin foam.
 13. Thegasket of claim 10 wherein said main body includes a pair of passagesextending through said ring shape upper portion for receiving boltssecuring said toilet base and toilet flange together with said main bodythere between.
 14. The gasket of claim 10 wherein said ring shape upperportion has a height of at least one inch between said upper surface andsaid lower surface to accommodate a seal with said toilet flangeregardless of variations in positioning of said toilet flange relativeto said building floor even though said toilet flange is above or belowsaid top surface of said building floor.
 15. A wax-less, repositionablegasket for providing a liquid and gas seal between a toilet base and atoilet flange provided on a drain conduit to which the toilet base ismountable comprising: a main body of polyurethane integral skin foamconstruction having a density between 0.04 to 0.4 gm/cc with said formconstruction extending throughout said main body and having a ring shapeupper portion for acting as a seal between a toilet base and a toiletflange on a drain conduit and a truncated conical extension integralwith said ring shape upper portion that is extendable into said toiletflange on said drain conduit to direct liquid flow, said main body hasan outer skin integral therewith providing structural stability to saidconstruction maintaining a seal despite varying loads thereon by saidtoilet base and despite repositioning thereof.
 16. The gasket of claim15 wherein the integral skin foam is polyether based.
 17. The gasket ofclaim 16 wherein BHT is present in the polyether providing ananti-microbial construction.
 18. The gasket of claim 16 and furthercomprising plumbers grease applied to said main body.